A generalised framework for designing topological interlocking structures from monomorphic elements

Topological interlocking (TI) structures, known for their superior energy dissipation, damage tolerance, and adaptability, are gaining increasing attention as innovative solutions to advanced structural designs. In this study, a general framework is developed for designing TI elements with curved contact surfaces, enabling the creation of monomorphic elements through a matched concavo-convex interface. The element shapes are controlled by parameters such as polygon type, polygon length, curve function, and element thickness. This approach can be applied to designing TI elements for both planar and non-planar structures. Validation is achieved through the design of 24 planar and 12 non-planar TI elements, along with two 3D-printed prototypes. Furthermore, the impact performance of typical TI plates is compared to that of a monolithic structure to demonstrate the effectiveness of the generalised interlocking mechanism. ● A general framework is developed for creating TI elements with curved interfaces. ● The proposed approach is applicable to both planar and non-planar structures. ● The element morphology is governed by four design parameters. ● The proposed approach offers a vast range of design possibilities.